Rusty s JL Winch Mount RR-WM55-JL INSTALLATION INSTRUCTIONS

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1 Rusty s JL Winch Mount RR-WM55-JL INSTALLATION INSTRUCTIONS Introduction: Rusty s recommends that this installation be performed by a certified automotive technician or a person with professional mechanical knowledge. Installing this kit without this expertise may jeopardize the handling and safety of the vehicle. Read instructions several times before starting. Be sure you have all the needed parts and know where they install. Read each step completely as you go. Exhaust modifications may be necessary. Prior to drilling or cutting, check behind the surface being worked on for any wires, lines, or hoses that could be damaged. After any drilling or cutting, remove burrs and grind smooth any surfaces. An inclinometer or similar tool may be needed to measure driveshaft angles before and after the installation. Warning: It is the owners responsibility to inspect all Rusty s products for proper torque specs to prevent loosening of components. Seat belts and shoulder harnesses should be worn at all times. Re-check all bolts and nuts after the first 100 miles and after any off-road usage during the first 300 miles. Although all of our products are made from the highest quality materials possible, they are not a substitute for Safe and Careful driving. In other words, have good safe on-road / off-road sense. Know the terrain, the speed limitations, and any obstacles that may lie ahead. Please remember to preserve our right to enjoy public land through the proper use of off-road vehicles. Before Starting Installation: 1. Carefully Read all warnings and instructions completely before beginning. 2. Verify all parts have been received in this kit by checking the parts list on page#2 of this document. 3. Only install this kit on the vehicle for which it is specified. 4. Park the vehicle on a clean, dry, flat, level surface and block the tires so the vehicle cannot roll in either direction. Last Revised: 2/14/ Be certain the vehicle is safely secured on jack stands or a vehicle lift prior to working around or under a vehicle. Never rely on a jack alone to support a vehicle s weight; use appropriately rated stands to support the vehicle s frame an any other heavy components. 1

2 Compatible Winch Model Information Note: Please read the following information carefully to ensure fitment of winch. Please ensure that your winch is no larger than any of the listed dimensions. If larger, we can not ensure product fitment. Winch Dimensions: 21.8 (555mm) Length x 6.3 (160mm) Depth x 7.6 (193mm) Height The following winch models have been confirmed to fit! Warn VR Series Warn M8 Series Warn 9.0RC Warn XDi Warn XD Superwinch Tiger Shark Superwinch LP Series Ramsey REP Series Ramsey Patriot Series Parts List: Note: Please be sure that you have all the provided parts listed below before continuing with the installation. Part # DESCRIPTION: Quantity RR-WM55-JL Rusty's Winch Mount JL Wrangler 1 RR-WM55-JL-FFP Fairlead Face Plate 1 FA M8 x 1.25mm Grade 8 Hex Nut /2"-13 x 1 Length Grade 8 Hex Head Cap Screw /2"-13 Grade 8 Hex Lock Nut 2 FA M12 x 1.75mm x 25mm Length Hex Head Cap Screw 2 FA M12 x 1.75mm Grade 8 Hex Nut 2 2

3 Installation Instructions 1. Cover the bottom portion of the grill with masking tape to prevent from accidentally damaging the grill during the installation process. 2. Remove the two plastic pins that secure the frame cover to the frame behind the front bumper. Use a small flat head screwdriver to remove the pins by placing the driver under the head of the plastic pins and prying upward. Discard the plastic frame cover as this will not be reused. 3. Disconnect the wiring harness on the passenger side of the frame rail that is for the fog lights located on the front bumper. 3

4 4. With the use of a T45 Torx driver, remove the factory (Qty: 5) T45 Torx head bolts that secure the top cover located in the center of the bumper. Discard the top cover as this will not be reused. Retain the (Qty: 5) T45 Torx head bolts to be reused. 5. Insert the (Qty: 5) T45 Torx head bolts back into the five-hole locations and install the supplied (Qty: 5) M8 x 1.25mm Grade 8 Hex Nut to each of the bolts. (Note: This step is a cosmetic step to keep from leaving open holes in the bumper.) 4

5 6. With the use of a 13mm socket, remove the front lower skid plate by removing the factory hardware that secures the skid plate to the bumper (5 mounting points) and the frame drops (2 mounting points). Retain the skid and hardware to be reinstalled. 7. With the use of an 18mm socket, remove the (Qty: 8) (Qty: 4 Per Side) factory nuts located on both the inside and outside of the frame rail mounting points on both the driver and passenger side of the vehicle to remove the front bumper. Place the front bumper on a soft surface to prevent scratching the finish. Retain all hardware to be reused. 8. From the inside of the bumper, remove the front plastic cover plate by pressing against the tabs and pushing the cover outward. 5

6 9. With the bumper facing upward, place the winch fairlead on top of the face plate and install with the supplied 1/2"-13 x 1 Length Grade 8 Hex Head Cap Screw and 1/2"-13 Grade 8 Hex Lock Nut as pictured below. Install so that the 1/2"-13 Grade 8 Hex Lock Nut is located on the inside of the bumper. Directly align the face plate and the fairlead and fully tighten the supplied 1/2 hardware. 10. With the use of a 16mm socket, remove the factory 10mm bolts that secure the frame tie-in bracketry to the frame. These are located on the inside of the frame rails as pictured below. This only applies to the inside frame rail tie-in bracketry. Retain the bolts as they will be reused. 6

7 11. Place the supplied Rusty s winch plate inside the frame rails and install the 16mm head bolts where the frame rail tie-ins were removed as pictured below. Only slightly tighten these bolts to allow a slight up and down movement. 12. Install the supplied (Qty:2) M12 x 1.75mm x 25mm Length Hex Head Cap Screws and (Qty:2) M12 x 1.75mm Grade 8 Hex Nuts holding the winch plate to the frame rails. Install the 12mm bolt in driver side bottom hole and passenger side upper hole. This step is to correctly line the winch plate up for further steps. Fully tighten the supplied 12mm bolts on the driver and passenger side. Then Fully tighten the 10mm (16mm head bolt) on the frame rail tie-ins to 45 ft. lbs. 7

8 13. Install the winch to the winch plate with the supplied hardware that comes with the winch. Fully tighten to the winch manufacturer s torque specs. Disengage the winch and pull approximately 1 foot of cable out. 14. Remove the (Qty:2) M12 x 1.75mm x 25mm Length Hex Head Cap Screws and (Qty:2) M12 x 1.75mm Grade 8 Hex Nut that were installed during step 12. Discard the hard as these were just used for alignment purposes and will not be needed for assembly. 15. Using an assistant, reinstall the front bumper on the JL. Install the factory nuts at each of the 4 mounting points on the frame rail. Fully tighten to 66 ft. Lbs. 16. Pull the cable through the roller fairlead and fasten the hook in place. 17. Route the power and ground wires to the battery, making sure they are clear of any moving parts or extreme heat. Zip tie to secure the wires. 18. Place the front lower skid plate back into position and reinstall the factory hardware (7 mounting points) and fully tighten. 19. Remove masking tape from the lower grill. 20. You have now completed the installation. 8

9 Installation Instructions It is the owners responsibility to inspect all Rusty s products for proper torque specs to prevent loosening of components. Seat belts and shoulder harnesses should be worn at all times. Re-check all bolts and nuts after the first 300 miles and after any off-road usage during the first 300 miles. Although all of our products are made from the highest quality materials possible, they are not a substitute for Safe and Careful driving. In other words, have good safe on-road / off-road sense. Know the terrain, the speed limitations, and any obstacles that may lie ahead. Please remember to preserve our right to enjoy public land through the proper use of 9